Electrical connectors – With insulation other than conductor sheath – Metallic connector or contact secured to insulation
Reexamination Certificate
2000-06-12
2001-11-20
Patel, Tulsidas (Department: 2839)
Electrical connectors
With insulation other than conductor sheath
Metallic connector or contact secured to insulation
C361S813000
Reexamination Certificate
active
06319072
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to an insert-molded body and a molding method thereof and more particularly to an insert-molded body used, for example, in the antilock braking system applied to a motor vehicle.
2. Description of the Related Art
Conventionally, an insert-molded body as shown in
FIG. 16
is suggested.
As is shown in
FIG. 16
, an insert-molded body
80
has a primary molded body
81
to be formed by the first molding, which primary molded body
81
is provided with a locking group
83
in a resin portion
82
. And, a terminal assembly
84
consisting of a plurality of strip terminals
85
is assembled to the locking group
83
(cf. FIG.
18
). The primary molded body
81
and the terminal assembly
84
are formed in a L-shape. As shown in
FIG. 17
, the locking group
83
is molded in both of an upper end surface
82
a
and a back
82
b
of the resin portion
2
.
With respect to the above insert-molded body
80
, however, a pair of metal molds (not illustrated) and another metal mold (not illustrated) to slid in a direction crossing at a right angle to an opening-and-closing direction of the pair of metal molds are required in order to form the above locking groups
83
. Therefore, the structure of metal molds are complicated. And, the strip terminal
85
of the terminal assembly
84
is to be assembled to the locking group
83
one by one, which takes a lot of time or trouble to assemble the terminal assembly
84
to the primary molded body
81
.
SUMMARY OF THE INVENTION
In view of the foregoing, an object of the present invention is to provide an insert-molded body and a molding method thereof wherein the structure of a metal mold for forming a primary molded body is simplified and trouble to assemble a terminal assembly to the primary molded body is reduced.
In order to achieve the above-described object, as a first aspect of the present invention, a insert-molded body comprises: a primary molded body having a first resin portion and a second resin portion; a terminal assembly consisting of one or a plurality of strip terminals; a bent portion formed on the terminal assembly and bent in a suitable angle; a first engaging portion and a second engaging portion protrusively provided on respective sides of the bent portion in a same direction; a first abutting face and a second abutting face provided on the first engaging portion and the second engaging portion, respectively; and a first end face and a second end face provided on the first resin portion and the second resin portion, respectively, wherein the first abutting face and the second abutting face abut against the first end face and the second end face, respectively, due to elastic restoring force arising on the terminal assembly by changing a bending angle of the bent portion.
As a second aspect of the present invention, in the structure with the above first aspect, the first and second engaging portions of the terminal assembly are provided with respective inclined planes to facilitate abutment against the respective first and second end faces.
As a third aspect of the present invention, in the structure with the above first aspect, the terminal assembly is tabular.
As a fourth aspect of the present invention, in the structure with the above second aspect, the terminal assembly is tabular.
As a fifth aspect of the present invention, a molding method of an insert-molded body comprises the steps of: molding a primary molded body having a first resin portion and a second resin portion having a first end face and a second end face, respectively; forming a terminal assembly consisting of one or a plurality of strip terminals; forming a bent portion by bending the terminal assembly in a suitable angle; protrusively providing a second engaging portion and a first engaging portion on the terminal assembly at respective sides of the bent portion in a same direction; forming a first abutting face and a second abutting face on the first engaging portion and the second engaging portion, respectively; hanging the first abutting face on the first end face of the first resin portion; hanging the second abutting face on the second end face of the second resin portion, while elastically deforming the terminal assembly; and holding the terminal assembly on the primary molded body by means of elastic restoring force arising on the terminal assembly.
According to the above-described structure of the present invention, the following advantages are provided.
(1) The bent portion is provided on the terminal assembly, the terminal assembly is elastically deformed about the bent portion, and the first and second abutting faces of the terminal assembly are engaged with the end planes of the first and second resin portions. Therefore, the assembled state between the primary molded body and the terminal assembly can be securely held due to the elastic restoring force arising on the terminal assembly, thereby eliminating to form a means for assembling the terminal assembly to the primary molded body at the stage of the primary molding. That is, the structure of the metal mold used to mold the primary molded body can be simplified, and manufacturing cost of the primary molded body can be reduced.
(2) Because the terminal assembly consisting of one or a plurality of strip terminals is capable of bending in a suitable angle, the terminal assembly can be elastically deformed about the bent portion. The first engaging portion and the second engaging portion are protrusively-provided on the respective sides of the bent portion, which first and second engaging portions are provided with the respective first and second abutting faces. Accordingly, the first abutting face can be hung on the end plane of the first resin portion, and the second abutting face can be hung on the end plane of the second resin portion after the terminal assembly is elastically deformed. That is, the terminal assembly can be easily assembled to the primary molded body by means of elastically deforming the terminal assembly. And, the assembled state between the primary molded body and the terminal assembly can be securely held due to the elastic restoring force arisen on the terminal assembly. Therefore, because the strip terminals constituting the terminal assembly need not to be assembled to the primary molded body one by one, trouble or time necessary for forming the insert-molded body can be reduced.
The above and other objects and features of the present invention will become more apparent from the following description taken in conjunction with the accompanying drawings.
REFERENCES:
patent: 3173732 (1965-03-01), James
patent: 3960424 (1976-06-01), Weisenburger
patent: 6068523 (2000-05-01), Takahashi
Armstrong Westerman Hattori McLeland & Naughton LLP
Hyeon Hae Moon
Patel Tulsidas
Yazaki -Corporation
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